Array of planar membrane modules for producing hydrogen

Abstract

A shared or common environment membrane reactor containing a plurality of planar membrane modules with top and bottom thin foil membranes supported by both an intermediary porous support plate and a central base which has both solid extended members and hollow regions or a hollow region whereby the two sides of the base are in fluid communication. The membrane reactor operates at elevate temperatures for generating hydrogen from hydrogen rich feed fuels.

1. A hydrogen separation unit with an array of planar members in a shared environment, comprising:
 a planar base with a top, bottom and outer side wall, the base having a plurality of solid extensions reaching inward from at least one side wall of the base forming a hollow region of channels within the base, wherein the hollow region is fluidly connected to one or more outlet port; 
 a plurality of surface coated perforated plates containing a plurality of perforations having size between 0.01″ and 0.02″; 
 said plurality of plates contain thickness of between 0.008″ and 0.02″; 
 each of said plurality of plates contains open areas greater than 45%, and 
 each of said perforated plates contains a surface coating except for a margin of between 0.09″ and 0.2″ from edges of said plates, wherein the surface coating is selected from said group consisting of titanium nitride, tungsten cobalt carbide, alumina, zirconia, yttria stabilized zirconia, and wherein the surface coating is of a thickness of between 3 and 20 microns; 
 a plurality of planar hydrogen separation membranes in fluid communication with each other, such that the plurality of hydrogen separation membranes have a shared environment; and, 
 a plurality of frames; 
 wherein each of said perforated plates is disposed on a corresponding one of said top and bottom of said base and between said base and a corresponding one of said plurality of hydrogen separation membranes, and 
 wherein each of said plurality of hydrogen separation membranes is disposed between a corresponding one of said plurality of perforated plates and a corresponding one of said plurality of frames. 
 
     
     
       2. The unit of  claim 1 , wherein hydrogen that is transported through the plurality of hydrogen separation membranes is collected in said hollow region of said base and routed out as high purity hydrogen through at least one outlet port. 
     
     
       3. The unit of  claim 1 , wherein each of said plurality of frames contains a central rib. 
     
     
       4. The unit of  claim 1  wherein said base is made of Inconel 600 with a surface finish of about 63 micro inches or smoother. 
     
     
       5. The unit of  claim 1  wherein spacing between said solid extensions is between about 0.062″ and about 0.125″. 
     
     
       6. A hydrogen separation unit with an array of planar members in a shared environment, comprising:
 a planar base with a top, bottom and outer side wall, the base having a plurality of solid extensions reaching inward from at least one side wall of the base forming a hollow region of channels within the base, wherein the hollow region is fluidly connected to one or more outlet port; 
 a plurality of surface coated perforated plates; 
 a plurality of planar hydrogen separation membranes each of said plurality of hydrogen separation membranes is a foil of an alloy of palladium with a thickness of 10-30 microns; and 
 said length and width of said foil is 0.005″ less than that of said base in fluid communication with each other, such that the plurality of hydrogen separation membranes have a shared environment; and, 
 a plurality of frames; 
 wherein each of said perforated plates is disposed on a corresponding one of said top and bottom of said base and between said base and a corresponding one of said plurality of hydrogen separation membranes, and wherein each of said plurality of hydrogen separation membranes is disposed between a corresponding one of said plurality of perforated plates and a corresponding one of said plurality of frames. 
 
     
     
       7. The unit of  claim 6  wherein said alloy of palladium consists of 75-77% palladium, and 23-25% silver. 
     
     
       8. A planar hydrogen separation membrane module, comprising:
 a rectangular metal base having a hollow region, rounded corners, at least two outlet ports and at least two hydrogen outlet tubings; 
 a perforated plate with a thickness of 0.008″ to 0.020″ disposed on either side of said base, said plate containing 0.01″ to 0.02″ perforations, and containing a surface coating from said group consisting of titanium nitride, tungsten cobalt carbide, alumina, zirconia, yttria stabilized zirconia of thickness 8-10 microns that covers said plate with said exception of a margin of 0.1″ from said edges of said plate; 
 a 10 to 30 micron thick Pd/Ag hydrogen separation membrane foil disposed on said surface of said perforated plates that is not in contact with said base; 
 a frame of thickness 0.008″ disposed on said surface of said foils that is not in contact with said hydrogen separation membrane foil; 
 wherein said base, said perforated plate and said frame made of Inconel 600 with a surface finish of 63 micro inches or smoother; and, 
 wherein said perforated plate, said hydrogen separation membrane foil, and said frame are combined with a leak tight seal from laser welding.